CAT PORTABLE GENERATORS Manuel utilisateur

Catégorie
Groupes électrogènes
Taper
Manuel utilisateur
5016075-05
Owner's Manual
RP3600, RP5500, RP6500,
RP6500 E, RP7500 E and RP8000 E
Portable Generators
2
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills, and tools to perform
these functions properly.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are
identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”,
“WARNING” or “CAUTION”.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. You must not use this
product in any manner different from that considered by this manual without first satisfying yourself that
you have considered all safety rules and precautions applicable to the operation of the product in the
location of use, including site-specific rules and precautions applicable to the worksite. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar is
used, you must satisfy yourself that it is safe for you and for others. You should also ensure that you are
authorized to perform this work, and that the product will not be damaged or become unsafe by the
operation, lubrication, maintenance, or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems
may be performed by any repair establishment or individual of the owner's choosing.
This manual contains safety, operation, and maintenance information. This manual should be stored near
the product. Read, study and keep it with the literature and product information.
Consumer Arbitration Clause
The Limited Warranty included in this User Guide contains important legal terms including, but not limited
to, a Consumer Arbitration Clause calling for mandatory individual arbitration and waiving the ability to
bring a case as a class action. Please review this carefully.
California Proposition 65 Warning
3
Table of Contents
Consumer Arbitration Clause .................................................................................................................... 2
California Proposition 65 Warning ............................................................................................................... 2
SAFETY MESSAGES ................................................................................................................................... 5
Additional Messages ................................................................................................................................. 6
Battery (if equipped) .................................................................................................................................. 6
Special Requirements ............................................................................................................................... 7
ASSEMBLY .................................................................................................................................................... 8
Feet Assembly .......................................................................................................................................... 8
Wheel Assembly ....................................................................................................................................... 8
Battery Connection (If equipped) .............................................................................................................. 8
Oil .............................................................................................................................................................. 8
Carriage brackets ...................................................................................................................................... 8
COMPONENT IDENTIFICATION .................................................................................................................. 9
RP3600, RP5500, and RP6500 ................................................................................................................ 9
RP6500 E, RP7500 E, and RP8000 E ...................................................................................................... 9
Engine Type & Serial Number ................................................................................................................. 10
CONTROLS ................................................................................................................................................ 11
Display ..................................................................................................................................................... 11
Generator Switch .................................................................................................................................... 11
Choke ...................................................................................................................................................... 11
CO DEFENSE
TM
& Shut Off System (If equipped) ................................................................................. 11
Fuel Switch .............................................................................................................................................. 12
Recoil Starter ........................................................................................................................................... 12
AC Circuit Breaker .................................................................................................................................. 12
CSA Circuit Breaker (If equipped) ........................................................................................................... 12
Low Oil Level Shutdown .......................................................................................................................... 12
120 VAC, 20 Amp, Duplex ...................................................................................................................... 12
RV Receptacle ........................................................................................................................................ 13
120 VAC, 120/240 VAC 30 Amp, Locking .............................................................................................. 13
GENERATOR OPERATION........................................................................................................................ 13
Optimal Generator Operating Conditions ................................................................................................ 13
Connection to Household Power Supply ................................................................................................. 13
Generator Grounding .............................................................................................................................. 13
AC Usage ................................................................................................................................................ 14
High Altitude Kits ..................................................................................................................................... 14
BEFORE STARTING ENGINE ................................................................................................................... 14
Engine Oil ................................................................................................................................................ 14
Fuel ......................................................................................................................................................... 14
Walk-Around Inspection .......................................................................................................................... 14
STARTING THE ENGINE ........................................................................................................................... 15
4
Recoil Start .............................................................................................................................................. 15
Electric Start (If equipped) ....................................................................................................................... 15
STOPPING THE ENGINE ........................................................................................................................... 15
MAINTENANCE .......................................................................................................................................... 15
Air Filter Check ..................................................................................................................................... 15
Cylinder Head - Clean ............................................................................................................................. 16
Engine Oil Level Check ........................................................................................................................ 16
Engine Oil Change ................................................................................................................................ 16
Engine Valve Lash Inspect/Adjust ....................................................................................................... 17
Fuel Line Replace ................................................................................................................................ 17
Fuel Tank Cap and Strainer Clean ...................................................................................................... 17
Generator - Inspect ................................................................................................................................. 17
Spark Arrestor - Inspect/Clean/Replace.................................................................................................. 17
Spark Plug Inspect/Adjust/Replace ...................................................................................................... 17
Battery (if equipped) Inspect/Replace .................................................................................................... 18
Walk-Around Inspection .......................................................................................................................... 18
STORAGE ................................................................................................................................................... 19
Storage for 1 to 3 months ........................................................................................................................ 19
Storage for more than 3 months ............................................................................................................. 19
TROUBLESHOOTING ................................................................................................................................ 20
SPECIFICATIONS ...................................................................................................................................... 21
COMBINED EXHAUST AND EVAPORATIVE EMISSIONS CONTROLS WARRANTY STATEMENT ...... 22
Your Warranty Rights and Obligations .................................................................................................... 22
Manufacturer’s Warranty Coverage ........................................................................................................ 22
Owner’s Warranty Responsibilities ......................................................................................................... 22
Defects Warranty Requirements: ............................................................................................................ 22
WARRANTY ................................................................................................................................................ 24
CONSUMER ARBITRATION CLAUSE: MANDATORY BINDING INDIVIDUAL ARBITRATION
INSTEAD OF COURT; CLASS ACTION WAIVER ................................................................................. 24
5
SAFETY MESSAGES
There may be several specific safety messages
on
your generator. Please become familiar with
all safety
messages.
Ensure that all safety messages are legible.
Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and
soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could
loosen
the adhesive that secures the safety
messages.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part
of
the generator that is replaced, install a new
safety
message on the replacement part.
Read the Manual
Do not operate or work on this generator unless
you have read and understand the instructions
and warnings in the Owner’s Manual. Failure to
follow the instructions or heed the
warnings could
result in injury or death. Proper care is your
responsibility.
Hot Surface / Do Not Touch /
Flammable Material
Hot parts or hot components can cause burns or
personal injury. Do not allow hot parts or
components to contact your skin. Use protective
clothing or protective equipment to protect your
skin. Hot exhaust presents a potential fire hazard.
Be sure that nothing flammable is within 1.5
meters of the exhaust.
Carbon Monoxide
Operating a generator indoors can kill you in
minutes. Generator exhaust contains carbon
monoxide. Carbon monoxide is a poison that
you cannot see or smell. Never operate a
generator inside a home or garage, even if
doors and windows are open. Only operate a
generator outdoors and away from windows,
doors, and vents. Always direct engine exhaust
away from occupied structures. If anyone
experiences dizziness, headaches, nausea, or
tiredness get to fresh air immediately and seek
medical attention. Ventilate the area thoroughly
before occupying again.
The carbon monoxide shutoff system is not a
substitute for safe generator operation. Do Not
adjust or modify the carbon monoxide shutoff
system. Failure to follow instructions can cause
the system to malfunction which can result in
hazardous conditions.
DANGER
PELIGRO
Utiliser un générateur à
l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES. Les gaz
d’échappement du générateur
contiennent du monoxyde de
carbone. C’est un gaz toxique
invisible et inodore.
NE JAMAIS utiliser à l’intérieur
d’une maison ou d’un garage,
MÊME SI les portes et les
fenêtres sont ouvertes.
Utiliser UNIQUEMENT à
l’EXTÉRIEUR et loin des
fenêtres, portes et ventilations.
Si usa un generador en
interiores, MORIRA EN POCOS
MINUTOS. El escape del
generador contiene monóxido
de carbono. Es un veneno que
no tiene olor ni se puede ver.
NUNCA lo use dentro de una
casa o garaje. AUN si las
puertas y vantanas están
abiertas.
Sólo úselo en EXTERIORES
y lejos de ventanas, puertas y
ductos de ventilación.
6
Electrocution
Shock/Electrocution Hazard: Do not
operate this
equipment or work on this equipment
unless you
have read and understand the
instructions and
warnings in the Owner’s Manual. Failure to
follow the
instructions or heed the warnings will
result in
serious injury or death.
Operation of this equipment may create sparks
that can start fires around dry vegetation. A spark
arrestor may be required. The operator should
contact local fire agencies for laws or regulations
relating to fire prevention requirements.
Electrical backfeed into a utility’s distribution
system can cause property damage, severe
injury, or death.
Electrical backfeed warning. Do not connect
generator to a building’s electrical system unless
using an isolation (transfer) switch installed by a
certified, licensed electrician. CA H&S Code
119075 & 119080.
.
Additional Messages
Do not operate in wet
conditions.
Do not refuel near open
flames. Do not refuel while the
engine is running. Do not
smoke while refueling.
Maintain a minimum distance
of 5 feet (1.5 meters) from
other objects.
Ensure that the unit is
properly grounded.
Battery (if equipped)
1. Do not expose battery to temperatures
above 60 C (140 F).
2. Do not reverse the positive (+) or negative
(-) terminals or short-circuit the battery in
any way.
3. Do not allow charge voltages in excess of
40 volts.
4. If the battery becomes hot to the touch,
stop charging. Allow battery to cool before
charging.
5. Do not open, disassemble or modify the
battery in any way.
6. Do not connect the battery to other
batteries in any way.
7. Do not over-discharge the battery. It may
damage the battery or shorten the battery
life.
8. A flammable hazard may exist if the battery
is physically damaged.
9. Failure to follow these instructions may
present risk of explosions, fire or high
temperatures.
CAUTION
7
Special Requirements
Electrical equipment, including lines and plug
connections shall be covered and protected
from moisture.
The circuit breakers shall match the generator
specifications. If the circuit breakers require
replacement, they must be replaced with a
circuit breaker of the same rating and
performance characteristics.
In any generator set
installation, the frame of the generator must be
connected to an earth ground. A ground terminal
is provided.
RP5500, RP6500, RP6500 E, RP7500 E, and
RP8000 E all have a permanent neutral
conductor between the stator winding and the
frame. RP3600 has a floating neutral.
For 120VAC duplex receptacles, use extension
cords rated for 125V at 20A or greater, and 30A
or greater for locking receptacles. For 240VAC
use extension cords rated for 250V at 30A or
greater. Use the shortest extension cord that
meets these requirements.
Wear a hard hat, protective glasses, and
other
protective equipment, as required.
When work is performed around an engine
that is
operating, wear protective devices for
ears in order
to help prevent damage to
hearing.
Do not wear loose clothing or jewelry that can
snag
on controls or on other parts of the
engine.
Ensure that all protective guards and all
covers are
secured in place on the engine.
Never put maintenance fluids into glass
containers. Glass containers can break.
Use all cleaning solutions with care.
8
ASSEMBLY
Feet Assembly
1. Set the frame of the unit on blocks to
provide sufficient clearance to install the
feet and wheels.
2. Align the mounting holes of the foot
bracket (2) with the mounting holes in
the frame.
3. Insert one 8 mm bolt (1) through each
set of mounting holes.
4. Install and hand tighten one 8 mm nut
(3) on each bolt.
5. Repeat steps 2 4 for the other foot.
6. Tighten all four nuts securely.
Wheel Assembly
1. Insert short end of axle (5) into the
mounting bracket on the frame.
2. Install one 10 mm nut (4) on the axle
and tighten securely to frame.
3. Place one large washer (6) on the long
end of the axle and install wheel (7) with
the bolt design facing out.
4. Install one large washer (6) onto the
axle.
5. Install one 10 mm locking nut (8) onto
the axle and tighten securely.
6. Repeat steps 1 5 for the other wheel.
7. Remove the blocking.
Battery Connection (If equipped)
RP6500 E, RP7500 E, and RP8000 E come with
the battery mounted in the battery holder. To
connect the battery:
1. The unit ships with the positive battery
cable (1) already connected.
2. Attach the cable with the black cap (2)
to the other cable with the connector.
Oil
Follow the Engine Oil Level-Check procedure to
add the proper amount of oil for the unit as
described in the Specifications chart.
Carriage brackets
The generator has 2 red carriage brackets fitted
underneath the base to prevent damage caused
by rough handling during transit.
IMPORTANT- These be must be removed
before use, otherwise the unit will vibrate
excessively and damage may occur.
7
6
4
6
8
5
2
9
COMPONENT IDENTIFICATION
RP3600, RP5500, and RP6500
RP6500 E, RP7500 E, and RP8000 E
1) Receptacle 120 VAC double
2) Fuel Cap
3) Circuit Breaker
4) CO Detector (If equipped)
5) Display
6) Generator Switch
7) Receptacle 30A 120 VAC RV*
Receptacle 120/ 240 VAC locking+
8) Panel Light
9) Fuel Valve
10) Recoil Start
11) Oil Drain
12) Air Filter Assembly
13) Air Filter
14) Choke Knob
15) CARB Canister (If equipped)
16) Spark Arrestor
17) Muffler
18) Engine
19) Spark Plug
20) Fuel Gauge
21) Fuel Tank Vent Pipe
22) Handle Assembly
23) Alternator
24) Oil Gauge / Oil Fill
25) Receptacles 120/240 VAC locking &
120 VAC locking
26) Battery
27) Starter
*RP3600
+RP5500
6
7
8
12, 13
10
17
16
18, 19
11
9
14
15
21
20
22
23
24
6
25
8
12, 13
10
17
16
18, 19
11
9
14
15
21
22
26
23
27
24
20
4
4
10
Engine Type & Serial Number
Cat® portable generators are identified with model numbers, serial numbers, and with performance
specification numbers. The model number and performance specifications are located on the ratings
plate (1) or the CSA ratings plate (3). The serial number is located on the serial number plate (2).
2
2
1
1
3
11
CONTROLS
Display
This generator is equipped with a display that can
show the voltage, frequency, total accumulated
hours of operation, and current hours. Use the toggle
switch (1) to change the readout of the display to the
desired setting.
The display will show 3 maintenance messages
when running: P-25 displays after the first 25 hours
running to remind the user to change engine oil. P-
50 displays after every 50 hours of use to remind
user to change engine oil and check spark arrestor.
P-100 displays after every 100 hours of use to
remind user to change engine oil and check spark
plug. These codes fade away after 6 minutes of use.
Generator Switch
Generator Switch Generator Switch
(Pull Start) (Electric Start)
For pull starting the generator, turn the generator
switch to the on position “I” before starting the
generator. For models with electric starting, turn the
generator switch to the start position “ ”. To turn
off the generator, turn the generator switch to the off
“0” position.
Choke
The choke is used to provide more fuel when starting
a cold engine. If the engine is cold, pull the choke
knob out before starting the engine. Once the engine
starts, slowly push in the choke knob.
CO DEFENSE
TM
& Shut Off System (If
equipped)
The (carbon monoxide) CO DEFENSE system
monitors the accumulation of carbon monoxide gas
while the generator is running and will shut off the
engine if the levels become dangerously high. The
CO DEFENSE
TM
on this generator is not a substitute
for an indoor CO alarm.
Whenever the CO DEFENSE has shut off the engine
there will be a light on the control panel that indicates
the reason. Read the CO Action Label (shown
above) for the next steps to take.
If the CO DEFENSE light is flashing “red” you must
leave the area immediately and relocate to an open
outdoor area. Ventilate the area thoroughly before
again occupying it. Ensure the generator is located in
an open outdoor area with the exhaust pointed away
from occupied structures. If anyone experiences
dizziness, headaches, nausea, or fatigue get to fresh
air immediately and seek medical attention.
If the CO DEFENSE light is a constant “orange” then
a system fault has occurred, or it is indicating that it
has reached the end of its life. This fault can only be
diagnosed and repaired by an Authorized Service
Provider.
The CO DEFENSE
monitors the accumulation of CO
gas from all sources in the area around the
generator. If the CO DEFENSE light is flashing “red”
this is not an error and safety measures must be
taken immediately.
Note: Tampering with the CO DEFENSE could result in
hazardous conditions and must be avoided.
Note The generator must not be operated in ambient
temperatures greater than 131
o
F (55
o
C) as this can
damage the CO DEFENSE.
12
Fuel Switch
The fuel switch controls the flow of the fuel from the
fuel tank to the carburetor.
Turn the fuel switch to the
on I” position before starting the engine. Turn the
fuel switch to the off "O"
position after stopping the
engine.
Recoil Starter
To start the engine, slowly pull the starter handle
until resistance is felt, then quickly pull the starter
handle the rest of the way.
Do not allow the starter handle to snap back against
the engine. Return it gently to prevent damage to the
starter.
AC Circuit Breaker
The generator comes equipped with circuit breakers
that protect the unit and the load from short circuit or
overload conditions. If the circuit breaker opens,
determine why the circuit breaker tripped before
closing the circuit breaker.
CSA Circuit Breaker (If equipped)
240V portable generators sold in Canada come with
an additional circuit breaker that will isolate all outlets
on the panel. This breaker must be in the “On”
position for the unit to provide power.
Low Oil Level Shutdown
The generator is equipped with a low oil level
shutdown that is designed to protect the engine from
damage caused by an insufficient amount of oil in
the crankcase. When the oil level in the crankcase
falls below the safe operating limit, the low oil level
shutdown will automatically shut off the engine.
120 VAC, 20 Amp, Duplex
The 120 VAC duplex receptacle is protected against
overload by a 20 Amp push to reset circuit breaker. It
also provides protection via a Ground Fault Circuit
Interruptor (GFCI) with press to Test and Reset
buttons (RP5500, RP6500, RP6500 E, RP7500 E,
RP8000 E). Use the receptacle to power a NEMA 5-
20, 120 VAC, single phase, 60 Hz electrical load
requiring 20 Amps of current.
Use only high quality, well insulated, 3-wire grounded
cords rated for 125 V at 20 Amps (or greater). Keep
extension cords as short as possible (less than 15
feet) to prevent voltage drop and overheating of wires.
O
I
On
Off
13
RV Receptacle
The 120 VAC RV outlet is protected against overload
by a 30 Amp push to reset circit breaker. Use a
NEMA TT-30 (120 VAC outlets) plug with this
receptacle.
Use the receptacle to power a 120 VAC, single
phase, 60 Hz electrical load.
120 VAC, 120/240 VAC 30 Amp, Locking
The 120 VAC and 120/240 VAC locking receptacles
are protected against overload by the following push
to reset circuit breakers:
Individual
Breaker
Main
Breaker
RP5500
23 A
RP6500
28 A
RP6500 E
28 A
RP6500 E CSA
27 A *
RP7500 E
30 A
31 A
RP7500 E CSA
30 A *
RP8000 E
30 A
33 A
*Double pole
Use a NEMA L5-30 (120 VAC outlets) or NEMA L14-
30 (120/240 VAC outlets) plug with this receptacle
(rotate to lock or unlock).
Use the receptacles to supply a single phase 60 Hz
120 V AC or 240 VAC electrical load.
GENERATOR OPERATION
Optimal Generator Operating Conditions
Temperature: 23
o
F to 104
o
F
(-5
o
C to 40
o
C)
Humidity below 95%
Height above sea level: < 3000 feet (900 m). If
the height of the operating area is over 900 m
high, output power will be reduced.
Standard operating conditions are 77
o
F (25
o
C) and
40% humidity. Generator power may be reduced due
to different ambient conditions and other factors such
as fuel quality.
Connection to Household Power Supply
This generator must be installed in accordance with
all applicable local laws and electrical codes. The
generator must be isolated from the utility and the
connection must be verified by a qualified electrician.
Generator Grounding
The National Electrical Code requires generators to
be grounded to an approved earth ground. Correct
grounding for the generator is necessary for optimum
engine performance and reduces the risk of electric
shock. Use the ground terminal to properly ground
the generator. Before using the ground terminal,
consult
a qualified electrician, electrical inspector, or
local authority having jurisdiction for local codes or
ordinances that apply for the intended use of the
generator.
1. RP3600 Earth Ground
2. RP5500, RP6500, RP6500 E, RP7500 E,
RP8000 E Earth Ground
1
2
14
AC Usage
Do NOT overload the generator. Exceeding the rated
power of the generator can damage the generator
and the electrical devices connected to it.
Motor-driven devices require a large starting current.
Make sure that the total power requirement of these
types of loads does not exceed the rated power of
the generator.
When the generator is used to power multiple loads
or electric appliances, start by connecting the
appliance with the highest starting power
requirements, followed by the second highest and
ending with the lowest.
High Altitude Kits
At higher altitudes, the standard fuel to air mixture is
too rich and will cause decreased performance and
increased fuel consumption. A rich mixture will also
foul the spark plug and make starting difficult.
Operation at higher altitudes for extended periods of
time may increase emissions.
Proper operation can be ensured by installing an
altitude kit when required. High altitude kits should
be installed by a qualified technician. Contact an
authorized service provider if the portable generator
will be operated at altitudes greater than 3000 feet
(0.9 km) above sea level.
Note: At elevations greater than 8000 feet above sea
level, the engine may experience decreased
performance even with the high-altitude kit installed.
BEFORE STARTING ENGINE
Engine Oil
Check the oil level before each use. Refer to the
Engine Oil - Check procedure in this manual.
Fuel
1. Check the fuel level gauge (1).
2. If the fuel level is low, remove fuel cap (2)
3. Check the strainer. If the strainer is dirty, clean
the strainer. Refer to Fuel Tank Cap and
Strainer Clean for instructions.
4. Add fuel. The use of a fuel stabilizer is highly
recommended as the unit may sit for long
periods of time before needed.
5. Install the fuel cap after fueling.
To avoid personal injury always use caution when
you are adding fuel:
Fuel the generator in a well-ventilated area.
Always stop the engine before fueling.
Allow the engine to cool before fueling.
Do not smoke while you are fueling the
generator.
Do not fuel the generator near open flames or
sparks.
Do not fill the fuel tank above the full line (3).
Avoid repeated or prolonged contact with skin
Avoid prolonged breathing of fuel vapor.
To avoid damaging the generator:
Use unleaded gasoline with an octane rating
greater than 86.
Do not mix oil with the gasoline.
Do not use gasoline with greater than 10%
ethanol content.
Do not use old gasoline.
Avoid getting dirt or water into the fuel tank.
Walk-Around Inspection
Perform the Walk-Around Inspection before each
use as described later in this manual.
1
2
3
4
15
STARTING THE ENGINE
Recoil Start
1. Isolate the generator from the utility
2. Unplug any electrical devices from the
receptacles.
3. Turn the fuel switch to the on "I" position.
4. Turn the AC circuit breakers to the off “0”
position (CSA models only).
5. If the engine is cold, pull out the choke knob.
6. Turn the generator switch to the on "I" position.
7. Slowly pull the starter handle until resistance is
felt,
then quickly pull the starter handle the rest
of the way. If the engine does not start, repeat
step 7 until the engine does start.
8. After the engine has warmed, push in the
choke knob.
9. Turn the AC circuit breaker to the on "I"
position.
Electric Start (If equipped)
1. Isolate the generator from the utility.
2. Unplug any electrical devices from the
receptacles.
3. Turn the fuel switch to the on I position.
4. Turn the AC circuit breakers to the off 0”
position (CSA models only).
5. If the engine is cold, pull out the choke knob.
6. Turn the generator switch to the start position “
and hold it there until the engine starts.
NOTE: Do not hold the generator switch in the start
position “ ” for more than 5 seconds. Holding the
generator switch in the start position “ ” for more
than 5 seconds will damage the starter. If the engine
fails to start, wait 10 seconds before trying again.
7. After starting the engine, immediately release
the generator switch so the switch can
automatically return to the on “Iposition.
8. After the engine has warmed, push the choke
knob in.
9. Turn the AC circuit breaker to the on "I"
position.
STOPPING THE ENGINE
1. Disconnect the generator / unplug all electrical
devices.
2. Turn the AC circuit breaker to the off “0” position
(CSA models only).
3. Turn the generator switch to the off “0” position.
4. Turn the fuel switch to the off 0 position.
Note: To stop the engine in an emergency, turn the
generator switch to the off “0” position.
MAINTENANCE
Ensure that all safety information, warnings, and
instructions are read and understood before any
maintenance procedures are performed.
Use service hours or calendar time, WHICH EVER
OCCURS FIRST, to determine the correct
maintenance intervals.
Stop the engine before servicing. Put the engine in
horizontal position and remove the spark plug cap to
prevent the engine from starting. Do not operate the
engine in an unventilated room or other enclosed
area.
When Required:
Fuel Tank Cap and Strainer Clean
Every Use:
Engine Oil Level Check
Walk-Around Inspection
First 25 Service Hours or 1 Month:
Engine Oil Change
Every Month:
Generator Inspect
Every 50 Service Hours or 3 Months:
Air Filter Check
Spark Arrester Inspect/Clean/Replace
Every 100 Service Hours or 6 Months:
Engine Oil Change
Spark Plug Inspect/Adjust/Replace
Every 300 Service Hours or 1 Year:
Carbon Brush Inspect/Repair/Replace
Cylinder Head Clean
Engine Valve Lash Check
Every 2 Years:
Fuel Line Replace
NOTE: Use only genuine Caterpillar parts.
Air Filter Check
A dirty air filter will restrict air flow into the
carburetor, will cause poor fuel economy, and
may damage the engine. To keep the generator in
good operating condition, service the air filter
regularly. Service more frequently when
operating the generator in extremely dusty areas.
Note: Never operate the generator without the air
filter in place. Operating the generator without the
air filter in place will result in rapid engine wear.
16
Remove the air filter cover bolt (3) and remove the
air filter cover (2).
Make sure that the air filter (1)
is clean and not damaged. If the air filter is dirty,
wash the filter. If the air filter is damaged, replace
the air filter.
Use a nonflammable solvent or a mixture of
household detergent and warm water to wash the
filter. Rinse the filter thoroughly to remove all of
the cleaning solution. After the filter has dried,
pour some engine oil onto the filter. Then
squeeze the filter to distribute the oil throughout
the filter and remove any excess oil.
Note: Do not wring out the filter. Wringing out the
filter may damage the filter.
Install the filter into the filter housing. Place the air
filter cover over the filter and reinstall the air filter
cover bolt.
Cylinder Head - Clean
Only qualified service personnel should perform
this maintenance procedure. Contact your local
service center to schedule this maintenance.
Engine Oil Level Check
Always check the engine oil with the generator on
a level surface and with the engine stopped.
1.
Remove the oil filler cap (1) and wipe the oil
level gauge (2) to clean it.
2.
Check the oil level by inserting the oil level
gauge into the filler neck. Do not screw the
oil filler cap in when checking the oil level.
3.
If the oil level is low (5), add the
recommended engine oil until the oil level
reaches the upper mark (4) on the oil level
gauge. Use the chart below to determine
which viscosity oil to use.
4.
After adding oil, install and tighten the oil
filler cap.
Note: Non-detergent and 2-stroke engine oils will
damage the engine and
must not be used.
Engine Oil Change
1. Operate the engine until it reaches normal
operating temperature. Stop the engine and
use a suitable container to collect the used
oil.
2. Remove the oil filler cap (1) and drain plug
(3) to drain the oil.
3. Reinstall the drain plug and tighten to 18 ±
2 lb ft (24 ± 3Nm).
4. Refill the oil and check the oil level. Refer to
Engine Oil Level Check.
5. Install and tighten the oil filler cap.
6. Dispose of the used oil properly.
Recommended Lubricant Viscosities for
Ambient Temperature
Oil
Viscosities
o
C
o
F
Min
Max
Min
Max
SAE 0W-40
-40
40
-40
104
SAE 5W-40
-30
50
-22
122
SAE 10W-30
-18
40
0
104
SAE 15W-40
-10
50
14
122
1
2
3
4
5
1
2
3
4
5
17
Engine Valve Lash Inspect/Adjust
Only qualified service personnel should perform
this maintenance procedure. Contact your local
service center to schedule this maintenance.
Fuel Line Replace
Only qualified service personnel should perform
this maintenance procedure. Contact your local
service center to schedule this maintenance.
Fuel Tank Cap and Strainer Clean
Wipe off the fuel cap (1) and surrounding area
before removing the fuel cap. Wiping off the fuel
cap and surrounding area before removing the
fuel cap helps to reduce the amount of
contaminants allowed into the fuel system.
If there is a build-up of debris in the fuel strainer
(2), remove the strainer and rinse out the
strainer. Allow the strainer to dry before installing
the strainer.
Generator - Inspect
Once a month start the engine and run the
engine until it reaches normal operating
temperature (about 20 minutes). Plug in a corded
device and turn on the device to ensure that the
generator is providing power. Once you have
verified that the generator is providing power,
turn off the device and unplug it. Then turn the
generator off.
Spark Arrestor -
Inspect/Clean/Replace
This unit has a spark arrestor fitted to the exhaust
outlet of the muffler. The spark arrestor should be
cleaned with a soft wire brush after every 50
hours or 3 months of use. The spark arrestor
should be replaced after every 100 hours of
operation or if it becomes damaged.
Hot Surface
Hot parts or hot components can cause burns or
personal injury. Do not allow hot parts or
components to contact your skin. Use protective
clothing or protective equipment to protect your
skin.
DO NOT perform this maintenance procedure
until the muffler has cooled.
Remove screws (2). Remove spark arrestor (1)
Check the spark arrestor. Carefully clean the
spark arrestor with a soft wire brush. If the spark
arrestor is damaged, replace the spark arrestor.
To install the spark arrestor, align the mounting
holes in the spark arrestor with the mounting
holes on the muffler. Insert screws (2) and tighten
securely.
Spark Plug Inspect/Adjust/Replace
Refer to the Specifications section of this manual
to determine the proper spark plug part number
and spark plug gap for your product.
1. Remove the side panel.
2. Remove the spark plug cap (3).
3. Use the plug wrench (1) to remove the
spark plug.
2
1
2
3
4
18
4. Visually check the spark plug to see if
it is
damaged. If the insulator is cracked, replace
the spark plug. If the electrode is damaged,
replace the spark plug.
5. Measure the plug gap (4) with a feeler
gauge. Adjust the gap as necessary by
carefully bending the side electrode. Refer
to Specifications for the correct gap for your
product.
6. Check the spark plug washer to ensure
proper working condition. If the washer is
damaged, replace the washer.
7. Install spark plug and tighten to 16 ± 2 lb ft
(22 ± 2 Nm). DO NOT overtighten as this
may damage the engine.
Battery (if equipped) Inspect/Replace
If the battery voltage is below 12.8 volts, charge
the battery. Recommended maximum continuous
charge voltage is 15 volts.
If the battery is unable to turn over the engine,
even after charging, check the battery terminals
are secure and free from corrosion.
If the battery requires replacement:
1. Disconnect the negative (-) cable first.
2. Disconnect the positive (+) cable
second.
To install the new battery:
1. Connect the positive (+) cable first.
2. Connect the negative (-) cable second.
NOTE: Use only genuine Caterpillar parts.
CAUTION - DANGER OF EXPLOSION IF
BATTERY IS INCORRECTLY REPLACED,
REPLACE ONLY WITH THE SAME OR
EQUIVALENT TYPE.
The used battery should be recycled in
accordance with local laws.
Walk-Around Inspection
Before starting the engine perform a visual
inspection of the unit. Look for:
Proper oil level
Proper fuel level
Good quality fuel
Fluid leaks
Loose clamps
Loose bolts
Cracked fuel line
Loose or frayed wiring
Built up debris
In addition, make sure that:
The ground terminal is properly connected
The circuit breakers are in OFF “ 0
position
19
STORAGE
When a generator is in storage, air may
condense and moisture may appear on the
windings. In order to minimize condensation,
always store the generator in a dry area. Cover
the generator with a protective cover that extends
to the ground. The cover should remain loose
around the generator in order to allow proper
ventilation.
The generator must not be stored in ambient
temperatures greater than 131
o
F (55
o
C) as this
can damage the CO Detector (if equipped).
Storage for 1 to 3 months
Remove any dirt, rust, grease, and oil from the
generator. DO NOT use a pressure washer to
clean the generator. Inspect the exterior. Make
any necessary repairs.
Add fuel stabilizer to the fuel tank to prevent the
gasoline from going bad. Start and run the engine
for 10 minutes to ensure that the fuel stabilizer
has been pulled in to the carburetor. Shut off the
engine and allow the engine to cool.
Turn the fuel valve to the off O“ position.
Move the generator to the storage place. Cover
the generator.
Storage for more than 3 months
Remove any dirt, rust, grease, and oil from the
generator. DO NOT use a pressure washer to
clean the generator. Inspect the exterior. Make
any necessary repairs.
Gasoline is extremely flammable and is explosive
under certain conditions. Drain the fuel in a well-
ventilated area with the engine stopped
and cool.
Never smoke or allow flames or sparks in the area
during
this procedure.
Make sure that the fuel valve is in the on I
position. Remove the fuel cap and the drain plug
(1) from the carburetor bowl and drain the fuel
into a suitable container. DO NOT save the fuel
for future use in the generator. Once the fuel has
completely drained from the system install the
drain plug into the carburetor. Turn the fuel valve
to the off O“ position. Apply a small amount of oil
to the threads on the fuel tank filler neck and
install the cap.
Change the engine oil.
Remove the spark plug and pour a small amount
of oil into the cylinder. Install the spark plug but
do not install the spark plug cap. Pull the starter
handle 3 times to distribute the oil over the
cylinder walls.
Remove the battery and place the battery in
storage. Periodically check the battery and
charge the battery when needed.
Move the generator to the storage place. Cover
the generator.
1
20
TROUBLESHOOTING
Issue:
Possible Cause:
Solution:
Check:
Engine Will
Not Start
Generator switch in the off “ 0 ”
position
Turn the generator switch to the
correct position.
Start the engine.
Choke knob in the wrong position
Place the choke knob in the
correct position.
No fuel
Fill the fuel tank.
Bad or contaminated fuel
Check the fuel.
Not enough oil in the engine
Check the oil level. If low, add
the recommended oil.
Dirty air filter
Clean the air filter.
No fuel at the carburetor
Make sure the fuel switch is in
the on "I" position.
Engine flooded
Wait 5 minutes.
No spark
Replace the spark plug.
For electric start, start the engine
using the recoil starter.
If the generator starts, check the
battery. If the battery is providing
less than 12.4 volts, replace.
If the engine still will not start:
Take the unit to an authorized service provider.
Engine Runs
Rough (no
load)
Dirty air filter
Stop the engine and check the
air filter. Clean if needed.
Start the engine /
check if it runs rough.
Choke knob in the wrong position
Place the choke knob in the
correct position.
If the engine still runs rough:
Take the unit to an authorized service provider.
Engine Shuts
Down
Out of fuel
Check the fuel. Fill the tank if
necessary.
Start the engine /
check if it shuts down.
Not enough oil in the engine
Check the oil level. If low, add
the recommended oil.
Dirty air filter
Clean the air filter.
Generator overloaded
Unplug some of the devices.
Shut off due to CO accumulation
& flashing red indicator
Follow all safety instructions on
CO Action Label
Shut off due to CO detector
system fault & constant orange
indicator
System fault or end of life indication. Take the unit to an
authorized service provider.
If the engine still shuts down:
Engine Runs
Rough (with
load)
Dirty air filter
Stop the engine and check the
air filter. Clean if needed.
Start the engine /
check if it runs rough.
Generator overloaded
Unplug some of the devices.
Defective device plugged in
Unplug defective device.
If the engine still runs rough:
Take the unit to an authorized service provider.
Engine Runs,
But Generator
Does Not
Provide
Power
Circuit breaker is open
Close the circuit breaker.
Start the engine /
check for power.
Bad connection
Stop the engine and check the
connections.
Defective power cord
Replace the cord.
Defective device plugged in
Unplug defective device.
If there is still no power:
Take the unit to an authorized service provider.
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CAT PORTABLE GENERATORS Manuel utilisateur

Catégorie
Groupes électrogènes
Taper
Manuel utilisateur